Floor mat and particulate laden material washing apparatus and method

ABSTRACT

A method of washing particulate laden material in a washer includes moving the particulate laden material from the intake of the washer to the discharge of the washer and through multiple modules or sectors. Liquid can be counter flowed in the washer interior along a flow path that is generally opposite the direction of travel of the particulate laden material. A specially configured recirculation/filtration arrangement removes a majority of particulate and organic matter from the washing fluid.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit of U.S. Provisional Patent Application Ser. No. 61/917,158, filed 17 Dec. 2013, which is hereby incorporated herein by reference.

Priority of U.S. Provisional Patent Application Ser. No. 61/917,158, filed 17 Dec. 2013, which is incorporated herein by reference, is hereby claimed.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable

REFERENCE TO A “MICROFICHE APPENDIX”

Not applicable

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a method and apparatus for cleaning floor mats such as when using a continuous batch washer or tunnel washer.

More particularly, the present invention relates to the cleaning of particulate laden material (such as floor mats, sand laden beach towels, work uniforms laden with metal shavings, or jeans laden with pumice rock such as the pumice rocks used in garments washing such as stone washed jeans) in a multiple module washer (e.g., tunnel washer) wherein a specially configured recirculation arrangement transmits liquid from a module (e.g., first module) to an intake or hopper and wherein a pump and filter in between the module and intake effect a removal of particulate material such as sand, metal shavings, or rocks during such recirculation.

2. General Background of the Invention

The purpose of a floor mat is to wipe or otherwise remove sand and dirt from the feet of people. Hence, dirty floor mats can be laden with significant quantities of heavy dirt or sand. Towels can be laden with sand and thus pose a problem for a resort hotel laundry. Metal shavings from uniforms used in the metal work industry can cause problems for a laundry. Other items to be laundered can be laden with pumice rocks used in garment washing such as stone washed jeans.

One of the problems with washing floor mats embedded with sand (or with organic compounds) is that once the sand is released from the mat into the washing water, the sand collects inside the shell of the washing machine such as in many of the modules of the tunnel washer. Periodically, the machine is programmed to insert a purge pocket which drains the water and hopefully most of the sand and organic compounds. If the sand and organic compounds are not removed, they build up in the machine. This causes the mats to not be cleaned. The build up of organic compounds causes the mats to have an extreme odor.

Patents have issued that are directed to batch washers or tunnel washers. The following table provides examples of such patented tunnel washers, each listed patent of the table being hereby incorporated herein by reference.

TABLE ISSUE DATE PAT. NO. TITLE MM-DD-YYYY 4,236,393 Continuous tunnel batch washer 12-02-1980 4,485,509 Continuous batch type washing machine 12-04-1984 and method for operating same 4,522,046 Continuous batch laundry system 06-11-1985 5,211,039 Continuous batch type washing machine 05-18-1993 5,454,237 Continuous batch type washing machine 10-03-1995 7,971,302 Integrated Continuous Batch Tunnel 07-05-2011 Washer 8,166,670 Clothes Dryer Apparatus with Improved 05-01-2012 Lint Removal System 8,336,144 Continuous Batch Tunnel Washer and 12-25-2012 Method 8,370,981 Integrated Continuous Batch Tunnel 02-12-2013 Washer 8,365,435 Laundry Press Apparatus and Method 02-05-2013 8,689,463 Clothes Dryer Apparatus with Improved 04-08-2014 Lint Removal System

BRIEF SUMMARY OF THE INVENTION

The present invention provides an improved method and apparatus for washing floor mats in a tunnel washer. By using a filter to filter a recirculation flow of fluid in the first module, most (e.g. 90 to 95%) of the sand and organic compounds are removed. This improves the performance of the washing machine, maintains the washing quality and eliminates any build up of sand or organic material.

By removing the sand in the first module, the washing machine stays clean and can be used to wash other materials such as linens. The present invention eliminates a laborious clean out of the interior of the washing machine.

The present invention includes a method of washing particulate laden material in a continuous batch tunnel washer. The method comprises the steps of providing a continuous batch tunnel washer having an interior, an intake, a discharge, a plurality of modules including a first module that is next to the intake, and a volume of liquid. The particulate laden material can be moved from the intake to the modules and then to the discharge in sequence. A washing chemical can be added to the volume of liquid, after a selected time period, and counter flowing a rinsing liquid along a flow path that is generally opposite the direction of travel of the material. A volume of liquid can be recirculated from the first module to the intake via a recirculation flow line. Particulate matter can be removed from the volume of liquid flowing in the recirculation flow line with a filter after the volume of liquid leaves the first module and before the volume of liquid reaches the intake.

In one embodiment, there can be a pump in the recirculation flow line.

In one embodiment, the pump can be in between the first module and the filter.

In one embodiment, the pump can be in between the filter and the intake.

In one embodiment, the particulate matter can include sand.

In one embodiment, the filter can remove particles from the volume of fluid via centrifugal action.

The present invention includes a method of washing particulate laden material in a continuous batch tunnel washer. The method comprises the steps of providing a continuous batch tunnel washer having an interior, an intake, a discharge, and a plurality of modules that segment the interior. The particulate laden material can be moved from the intake to the discharge. A washing chemical can be added to the modules to wash the particulate laden material with a combination of water and the washing chemical, after a selected time interval, counter flowing liquid in the washer interior along a flow path that is generally opposite the direction of travel of the particulate laden material in order to effect a rinse of the particulate laden material. Liquid can be recirculated from one of the modules to the intake via a recirculation flow line. Particulate material can be removed from the recirculating liquid with a filter.

In one embodiment, the present invention can further comprise boosting the flow rate in the recirculation flow line with a pump.

In one embodiment, the filter can filter sand as part of the particulate matter.

In one embodiment, the pump can be in between the module and the filter.

The present invention includes a particulate laden material washing apparatus. The apparatus of the present invention can include a continuous batch tunnel washer having an interior, an intake, a discharge, a plurality of modules including at least an upstream, first module that can be next to the intake and at least one downstream module next to the discharge, and a volume of liquid. The particulate laden material can move from the intake to the modules and then to the discharge in sequence. One or more counter flowing liquid flowlines can counterflow liquid along a flow path that can be from a downstream module to an upstream module. A recirculating liquid flow line can connect from the first module to the intake. A filter after the liquid leaves the first module and before the liquid reaches the intake.

In one embodiment, the apparatus can further comprise a pump in the recirculating liquid flow line.

In one embodiment, the pump can be in between the first module and the filter.

In one embodiment, the pump can be in between the filter and the intake.

In one embodiment, the filter removes particulate matter that can include sand.

In one embodiment, the filter removes particulate matter that can include organic waste material.

In one embodiment, the filter removes particulate material using centrifugal force.

In one embodiment, the filter continuously removes particulate matter from the recirculating liquid flow line as fluid flows in said recirculating liquid flow line.

The present invention includes a method of washing fabric articles that contain unwanted particulate matter. The method comprises the steps of providing a continuous batch tunnel washer having an interior, an intake, a discharge, a plurality of modules including a first module that is next to the intake, and a volume of liquid. The particulate laden material can be moved from the intake to the modules and then to the discharge in sequence. A washing chemical can be added to the volume of liquid, after a selected time period, can counter flowing a rinsing liquid along a flow path that is generally opposite the direction of travel of the material. A volume of liquid can be recirculated from the first module to the intake via a recirculation flow line. Particulate matter can be removed from the volume of liquid flowing in the recirculation flow line with a filter after the volume of liquid leaves the first module and before the volume of liquid reaches the intake.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:

FIG. 1 is a schematic diagram showing a preferred embodiment of the apparatus of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows a preferred embodiment of the apparatus of the present invention designated by the numeral 10. Washing apparatus 10 is used to wash floor mats that can contain undesirable material, particulate material such as sand, organic matter and the like. The apparatus of the present invention employs a multiple module tunnel washer 11. Tunnel washer 11 can be as shown and described in any one of the following US patents, each of which is incorporated herein by reference: U.S. Pat. Nos. 4,236,393; 4,485,509; 4,522,046; 5,211,039; 5,454,237; 7,971,302; 8,166,670; 8,336,144; 8,370,981; 8,365,435; and 8,689,463.

Tunnel washer 11 has an inlet end portion 12 with hopper 26 and an outlet end portion 13. The tunnel washer 11 provides a plurality of modules 14-17. The first module is module 14. The second module is module 15. The third module is module 16. The final module is module 17. It should be understood that more than four (4) modules can be provided. Fluid impregnated mats that exit the outlet end portion 13 of tunnel washer 11 enter an extractor or press (not shown) via a discharge 27 such as a discharge flow line or chute. The extractor removes excess water from the mats to be cleaned and transmits that excess water to water tank 29. Water from tank 29 flows via flow line 32 in the direction of arrow 28 from tank 29 to tank 33. A valve 18 can be provided in flow line 32.

Make up water can be added to tank 33 via flow line 22. The flow line 22 has a valve 21. The flow line 22 receives water from a water source 19 such as a city water supply. The flow line 22 can be provided with a back flow preventer or check valve 37. A flow meter 20 can be provided in line 22. The tank 33 is provided with a drain valve 23 that enables water to be discharged from tank 33 via drain valve 23 into sewer 24 as indicated by arrow 25 in FIG. 1.

FIG. 1 shows a recirculation line that recirculates fluid from the first module 14 via flow lines 52, 57 to hopper 26. Hopper 26 is at the inlet end portion 12 of tunnel washer 11. The hopper 26 is also receptive of floor mats to be cleaned. The floor mats are added to the hopper 26. From the hopper 26, the mats proceed in sequence to the first module 14, then to modules 15, 16, and then to module 17. From the module 17, the floor mats are transferred via a discharge 27 into a water extractor, press or the like water removal device.

A pump 30 can be used to transmit extracted water from tank 29 via flow line 32 to tank 33. Tank 29 has interior 31 for holding water that is routed to the tank 29 from the water extractor or press. Such water extractors or presses are commercially available.

Flow lines 34 and 35 enable water to be discharged from tank 33 to final module 17 or to any one of the modules 14, 15, 16 or to the hopper 26. Flow line 38 enables water to flow from line 35 to hopper 26. Flow line 39 enables water to flow from flow line 35 to module 14. Flow line 40 enables water to flow from flow line 35 to module 15. Flow line 41 enables water to flow from flow line 35 to module 16. Flow line 35 terminates at module 17. Flow line 34 also terminates at module 17. Pumps 36 can be used to provide pressure in the flow lines 34, 35.

Each of the flow lines 38, 39, 40, 41 and 34, 35 are provided with valves. Flow line 38 has valve 42. Flow line 39 has valve 43. Flow line 40 has valve 44. Flow line 41 has valve 45. Flow line 34 has valve 46. Flow line 35 has valve 47. Flow line 38 can have flow meter 48. Flow line 34 can have a flow meter 48.

Each of the modules 14, 15, 16, 17 can be provided with chemical injection such as alkaline injection 49, detergent injection 50 or other chemical injections such as finishing liquid, starch or any other washing or finishing chemical 63. Steam injection 51 can be provided at one or more of the modules 14, 15, 16 or 17 as indicated in FIG. 1.

The flow lines 52, 57 recirculate fluid from the first module 14 to hopper 26. The flow line 52 can be provided with a pump 53. The flow line 57 could also be provided with a pump. Filter 54 is placed at the end of flow line 52 and at the beginning of flow line 57. Filter 54 is preferably a centrifugal filter that removes undesirable particulate matter such as sand, organic matter or the like and deposits it in sand container 55 as indicated by arrow 56. Filter 54 can be for example a centrifugal type filter such as is shown and described in any of the following US patents, each of which is incorporated herein by reference: U.S. Pat. Nos. 5,320,747; 5,338,341; 5,368,735; 5,425,876; 5,571,416; 5,578,203; 5,622,545; 5,653,874; 5,894,995; 6,090,276; 6,143,175; 6,167,960; 6,202,543; 7,000,782; and 7,032,760.

Counter flow can be provided from one module to a previous module. Counter flow line 58 enables counter flow from module 17 to module 16. Flow line 59 enables counter flow from module 16 to module 15. Flow line 62 enables counter flow from module 15 to module 14. Each of the modules 14, 15, 16, 17 is provided with a valved drain 23 for enabling discharge of fluid to sewer 24. Module 14 can be provided with overflow drain line 60 which discharges fluid through valve 61 to sewer 24.

The following is a list of parts and materials suitable for use in the present invention:

PARTS LIST Part Number Description 10 washing apparatus 11 tunnel washer 12 inlet end portion 13 outlet end portion 14 module 15 module 16 module 17 module 18 valve 19 water source/flow line/city water supply 20 flow meter 21 valve 22 make up water line/flow line 23 drain valve/valved drain 24 sewer 25 arrow 26 hopper 27 discharge 28 arrow 29 water tank 30 pump 31 interior 32 flow line 33 tank 34 flow line 35 flow line 36 pump 37 back flow preventer/check valve 38 flow line 39 flow line 40 flow line 41 flow line 42 valve 43 valve 44 valve 45 valve 46 valve 47 valve 48 flow meter 49 alkaline injection 50 detergent injection 51 steam/steam injection 52 flow line 53 pump 54 filter 55 sand container 56 arrow 57 flow line 58 counter flow line 59 counter flow line 60 overflow drain 61 valve 62 counter flow line 63 other chemical injections/finishing liquid/starch

All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise.

The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims. 

1. A method of washing particulate laden material in a continuous batch tunnel washer, comprising the steps of: a) providing a continuous batch tunnel washer having an interior, an intake, a discharge, a plurality of modules including a first module that is next to the intake, and a volume of liquid; b) moving the particulate laden material from the intake to the modules and then to the discharge in sequence; c) adding a washing chemical to the volume of liquid; d) after a selected time period, counter flowing a rinsing liquid along a flow path that is generally opposite the direction of travel of the material in step “b”; f) recirculating a volume of liquid from one of the modules to the intake via a recirculation flow line; and g) removing particulate matter from the volume of liquid flowing in the recirculation flow line with a filter after the volume of liquid leaves the first module and before the volume of liquid reaches the intake.
 2. The method of claim 1 wherein in step “g” there is a pump in the recirculation flow line.
 3. The method of claim 2 wherein the pump is in between the first module and the filter.
 4. The method of claim 2 wherein the pump is in between the filter and the intake.
 5. The method of claim 1 wherein the particulate matter includes sand.
 6. The method of claim 1 wherein the filter removes particles from the volume of fluid via centrifugal action.
 7. A method of washing particulate laden material in a continuous batch tunnel washer, comprising the steps of: a) providing a continuous batch tunnel washer having an interior, an intake, a discharge, and a plurality of modules that segment the interior; b) moving the particulate laden material from the intake to the discharge; c) adding a washing chemical to the modules to wash the particulate laden material with a combination of water and said washing chemical; d) after a selected time interval and after step “c”, counter flowing liquid in the washer interior along a flow path that is generally opposite the direction of travel of the particulate laden material in step “b” in order to effect a rinse of the particulate laden material; and e) recirculating liquid from a first one of the modules to the intake via a recirculation flow line; and f) removing particulate material from the recirculating liquid of step “e” with a filter.
 8. The method of claim 7 further comprising boosting the flow rate in step “e” in the recirculation flow line with a pump.
 9. The method of claim 7 wherein the filter filters sand as part of the particulate matter.
 10. The method of claim 8 wherein the pump is in between the filter and the intake.
 11. The method of claim 8 wherein the pump is in between the module and the filter.
 12. A particulate laden material washing apparatus comprising: a) a continuous batch tunnel washer having an interior, an intake, a discharge, a plurality of modules including at least an upstream, first module that is next to the intake and at least one downstream module next to the discharge, and a volume of liquid; b) wherein the particulate laden material move from the intake to the modules and then to the discharge in sequence; c) one or more counter flowing liquid flowlines that counterflow liquid along a flow path that is from a downstream module to an upstream module; d) a recirculating liquid flow line connecting from the first module to the intake; and e) a filter after the liquid leaves the first module and before the liquid reaches the intake.
 13. The washing apparatus of claim 12 further comprising a pump in the recirculating liquid flow line.
 14. The washing apparatus of claim 13 further comprising wherein the pump is in between the first module and the filter.
 15. The washing apparatus of claim 13 wherein the pump is in between the filter and the intake.
 16. The washing apparatus of claim 12 wherein the filter removes particulate matter that includes sand.
 17. The washing apparatus of claim 12 wherein the filter removes particulate matter that includes organic waste material.
 18. The washing apparatus of claim 12 wherein the filter removes particulate material using centrifugal force.
 19. The washing apparatus of claim 12 wherein the filter continuously removes particulate matter from the recirculating liquid flow line as fluid flows in said recirculating liquid flow line.
 20. (canceled) 